Simulation-Guided Aerodynamic Design and Scaled Verification for High-Performance Sports Cars

High-performance sports cars rely on aerodynamics for stability and speed, but developing aero packages is challenging when wind tunnel testing is limited. In this study, we employed a simulation-guided design loop to maximize downforce and minimize drag on a sports car using Computational Fluid Dynamics (CFD). Thirteen aerodynamic modifications—including splitters, ducts, diffusers, and a Drag Reduction System (DRS)—were iteratively tested using CFD. To ensure numerical reliability, a mesh independence study and convergence analysis were performed, confirming stable aerodynamic predictions. The final configuration achieved an ~11× increase in downforce at 120 km/h (from about 320 N to 3588 N), meeting the design goal of roughly 2000 kg of downforce at 177 mph when scaled. This extreme downforce came with higher drag (CD ≈ 0.83), so a dual-mode approach was developed: a DRS configuration provides moderate downforce with 50% less drag (CD ≈ 0.41) for high-speed efficiency. A 1:12-scale wind tunnel test qualitatively supported the CFD predictions by visualizing wake narrowing and improved flow attachment. While quantitative force validation was not possible due to Reynolds mismatch and facility constraints, the qualitative results increased confidence in the CFD-based findings. Overall, the study demonstrates that substantial aerodynamic gains can be achieved under resource constraints, offering a practical framework for motorsport engineers and manufacturers to optimize aero kits when conventional full-scale testing is not accessible.